Process tube and carrier tray

ABSTRACT

The disclosure provides a system and method to safely and efficiently store and transport process tubes in a carrier tray comprising prior to and during amplification of nucleotides in the process tubes. The process tube disclosed includes a securement region having an annular ledge, a neck, and a protrusion. The securement region of the process tube can secure the process tube in a port of the carrier tray, but still allows the process tube to adjust or float in order to align the process tube into a rigid heater well of a thermal cycler.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/844,936, filed Sep. 3, 2015, which is a continuation of InternationalPatent Application No. PCT/US2013/032556, filed Mar. 15, 2013, entitled“PROCESS TUBE AND CARRIER TRAY.” The entire disclosures of theabove-referenced applications are hereby incorporated by reference intheir entirety.

BACKGROUND Field of the Development

The technology described herein generally relates to process tubes usedin amplification processes and the carrier trays in which the processtubes are securely stored for transport and processing, as well asmethods of making and using the same.

Description of the Related Art

The medical diagnostics industry is a critical element of today'shealthcare infrastructure. At present, however, in vitro diagnosticanalyses, no matter how routine, have become a bottleneck in patientcare. Understanding that diagnostic assays of biological samples maybreak down into several key steps, it is often desirable to automate oneor more steps. For example, a biological sample, such as those obtainedfrom a patient, can be used in nucleic acid amplification assays, inorder to amplify a target nucleic acid (e.g., DNA, RNA, or the like) ofinterest. Polymerase chain reaction (PCR), conducted in a thermal cyclerdevice, is one such amplification assay used to amplify a sample ofinterest.

Once amplified, the presence of a target nucleic acid, or amplificationproduct of a target nucleic acid (e.g., a target amplicon) can bedetected, wherein the presence of a target nucleic acid and/or targetamplicon is used to identify and/or quantify the presence of a target(e.g., a target pathogen, genetic mutation or alteration, or the like).Often, nucleic acid amplification assays involve multiple steps, whichcan include nucleic acid extraction and preparation, nucleic acidamplification, and target nucleic acid detection.

In many nucleic acid-based diagnostic assays, the biological,environmental, or other samples to be analyzed, once obtained, are mixedwith reagents for processing. Such processing can include combiningextracted nucleic acids from the biological sample with amplificationand detection reagents, such as probes and fluorophores. Processingsamples for amplification is currently a time-consuming and laborintensive step.

Processing samples for amplification often occurs in dedicated processtubes, used to hold the extracted DNA samples prior to and during theamplification process. In some instances, the process tubes are placeddirectly in a thermal cycler for amplification. In some instances, tosimplify the procedure, process tubes are first placed in a tube rackfor pre-amplification processing (such as filling up the tubes with theamplification reagents, drying the reagents, and marking the tubes byhot stamping them). The process tubes are often removed from the tuberack by a lab technician and placed individually and separately incontact with a heater unit of the thermal cycler. Placing the processtubes individually in the thermal cycler is inefficient, time consuming,and can be difficult to automate. Further, such processes aresusceptible to human error.

In some instances, racks containing the process tubes can be placeddirectly in the thermal cycler. However, this approach too has drawbacksbecause the process tubes may shift in the rack during handling andtransport and consequently will likely not line up correctly with theheaters of the thermal cycler. Additional intervention by a labtechnician is required align the tubes and fit them into the heaters ofthe thermal cycler. Furthermore, if the process tubes are not securelyconnected to the rack, the process may become dislodged during markingof the process tubes, being pulled up and out of the rack by thestamping apparatus.

Much of the difficulty with the handling and transport of process tubesin a rack stems from the shape of the tubes generally used inamplification processes. Process tubes are often conical in shape,having an outside diameter larger at the top of the process tube than atthe bottom of the process tube. Some process tubes are cylindrical inshape, having a constant diameter from top to bottom. The ports of therack in which the process tubes are placed must be of a greater diameterthan the largest outside diameter of the process tubes (at the top ofthe process tube). To address the tolerances associated withmanufacturing the process tubes and the rack, the ports in the rack areoften appreciably larger than the outside diameter of the process tubes,allowing the tubes to move around in the rack and potentially fall out.Without a secure fit in the rack, the process tube may tilt to one sideor another. With multiple process tubes in a rack, the tilting processtubes may bump into each other and break and/or cause loss of sampleand/or reagents stored therein. Furthermore, it can be very difficult toline up the differently tilted process tubes into the rigid heaters ofthe thermal cycler.

Thus, there is a need for process tubes and a tray that fit securelytogether to allow for safe and efficient handling and transport of theprocess tubes prior to and during amplification. Furthermore, there is aneed for process tubes that still have an ability to adjust or floatwithin the tray in order to facilitate alignment with the heaters of athermal cycler.

The discussion of the background herein is included to explain thecontext of the inventions described herein. This is not to be taken asan admission that any of the material referred to was published, known,or part of the common general knowledge as at the priority date of anyof the claims.

SUMMARY

Certain embodiments disclosed herein contemplate a process tube having asecurement region that includes an annular ledge, a protrusion, and aneck between the ledge and the protrusion. The process tube alsoincludes a body extending below the protrusion and a top ring extendingvertically up from the annular ledge which defines an opening to thetube.

In certain embodiments, an outside surface of the neck can be parallelto a longitudinal axis through the process tube. The protrusion caninclude an apex, an upper slope from the apex to the neck, and a lowerslope from the apex to the body. The angle of the upper slope on theprotrusion can be steeper than the angle of the lower slope on theprotrusion. The annular ledge of the process tube can have an uppersurface, a lower surface, and an outside surface. The protrusion canhave a larger outside diameter than the outside diameter of the neck.The annular ledge can have a larger outside diameter than the outsidediameter of the protrusion. The process tube can further include a basebelow the body which defines a bottom of the process tube.

Certain embodiments disclosed herein include a process tube strip havinga plurality of process tubes. The plurality of process tubes isconnected by a tab adjoining the annular ledges of the plurality oftubes.

Certain embodiments contemplate a process tube having an annular ledgeextending laterally from the tube, the annular ledge comprising an uppersurface, a lower surface, and an outer surface. The process tube caninclude a top ring extending vertically up from the upper surface of theannular ledge which defines an opening to the process tube. The processtube can further include an annular protrusion extending laterally fromthe process tube, at a location on the tube below the annular ledge. Theprotrusion can have an apex, an upper slope, and a lower slope. Theprocess tube can include a neck between the annular ledge and theprotrusion, a body below the protrusion, and a base which defines abottom of the tube.

Embodiments of the process tube disclosed can be configured to securelyfit in a carrier tray. The carrier tray can have a shelf and a base,such that the shelf has a plurality of ports through a top of the shelf,and the ports having an interior wall. In certain embodiments, theprotrusion of the process tube disclosed can have a larger outsidediameter than the diameter of the port in the carrier tray. The neck ofthe process tube can have a smaller outside diameter than the diameterof the port in the carrier tray. The process tube can be securely fitinto a port of the carrier tray.

In certain embodiments of the process tube, the lower surface of theannular ledge of the process tube can rest on an exterior of the shelftop and the upper slope of the protrusion can rest on a bottom edge ofthe interior wall of the port. A gap can exist between the neck of theprocess tube and the interior wall of the port and the gap can allow theprocess tube to tilt or adjust within the port of the carrier tray.

Further embodiments of the disclosure contemplate a system having acarrier tray with a plurality of ports therethrough and a process tubehaving a securement region. The securement region of the process tubecan include an annular ledge, a neck, and a protrusion. The securementregion of the process tube can fit securely in a port of the carriertray. In this system, the annular ledge and protrusion of the processtube can have outside diameters that are larger than the diameter of theport of the carrier tray and the neck of the process tube can have anoutside diameter that is smaller than the diameter of the port. When theprocess tube is securely fit in the port of the carrier tray, theprocess tube can tilt or adjust within the port of the carrier tray.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows an isometric view of an exemplary process tube strip asdescribed herein.

FIG. 1B is a side plan view of the process tube strip of FIG. 1A.

FIG. 1C is a top view of the process tube strip of FIG. 1A.

FIG. 1D shows an isometric view of another exemplary process tube stripas described herein.

FIG. 1E shows an isometric view of another exemplary process tube stripas described herein.

FIG. 2A is an isometric view of an exemplary, single process tube asdescribed herein.

FIG. 2B is a cross-sectional view of the process tube of FIG. 2A takenalong line 2B in FIG. 1C.

FIG. 3A shows an exemplary carrier tray, as described herein.

FIG. 3B shows a plurality of exemplary process tube strips in thecarrier tray of FIG. 3A.

FIG. 4 is a cross-sectional view of 12 process tubes positioned in thecarrier tray prior to securing the process tubes in the carrier tray.

FIG. 5 is a cross-sectional view of two exemplary process tubespositioned in the carrier tray prior to securing the process tubes inthe carrier tray.

FIG. 6A is a cross-sectional view, taken along line 6A in FIG. 3B, ofthe 12 process tubes of FIG. 4 after securing the process tubes in thecarrier tray.

FIG. 6B is a cross-sectional view, taken along line 6B in FIG. 3B, of aprocess tube strip positioned in the carrier tray after securing theprocess tubes in the carrier tray.

FIG. 7 is a cross-sectional view of the process tubes of FIG. 5positioned in the carrier tray after securing the process tubes in thecarrier tray.

FIG. 8 is an isometric view of an exemplary heater assembly of a thermalcycler.

FIG. 9 is a cross-sectional view of exemplary process tubes positionedin heater wells of a heater assembly, as described herein.

DETAILED DESCRIPTION

Before the embodiments are further described, it is to be understoodthat this invention is not limited to particular embodiments described,as such may, vary. It is also to be understood that the terminology usedherein is for the purpose of describing particular embodiments only, andis not intended to be limiting.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range and any other stated or intervening value in thatstated range is encompassed within the embodiments. The upper and lowerlimits of these smaller ranges may independently be included in thesmaller ranges and are also encompassed within the embodiments, subjectto any specifically excluded limit in the stated range. Where the statedrange includes one or both of the limits, ranges excluding either bothof those included limits are also included in the embodiments.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the embodiments belong. Although any methods andmaterials similar or equivalent to those described herein may also beused in the practice or testing of the embodiments, the preferredmethods and materials are now described.

It must be noted that as used herein and in the appended claims, thesingular forms “a,” “and,” and “the” include plural referents unless thecontext clearly dictates otherwise. Thus, for example, reference to “amethod” includes a plurality of such methods and equivalents thereofknown to those skilled in the art, and so forth.

Throughout the description and claims of the specification the word“comprise” and variations thereof, such as “comprising” and “comprises,”is not intended to exclude other additives, components, integers orsteps.

The process tubes and carrier tray described herein can be used togetherto provide a safe and efficient system of preparing, storing, andtransporting the process tubes prior to use in a thermal cycler and alsofor positioning the process tubes accurately and securely in the thermalcycler during amplification.

FIG. 1A shows an isometric view of an exemplary process tube strip 100according to the embodiments described herein. FIG. 1B is a side planview of the process tube strip of FIG. 1A. FIG. 1C is a top view of theprocess tube strip of FIG. 1A. As shown in FIGS. 1A-1C, the process tubestrip 100 is a collection of process tubes 102, connected together by aconnector tab 104. The exemplary process tube strip 100 can also includea top end tab 106, as shown in FIGS. 1A-1C, indicating the top of theprocess tube strip 100 and a bottom end tab 108 indicating the bottom ofthe process tube strip 100. The process tube strip 100 shown in FIGS.1A-1C includes eight process tubes 102 connected together in the processtube strip 100. One skilled in the art will immediately appreciatehowever, that in other embodiments, the process tube strip 100 caninclude, for example any other number of process tubes, e.g., 40, 30,20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 7, 6, 5, 4, 3, or 2process tubes 102 connected in the process tube strip 100. An embodimentof the process tube strip 100 can include an insignia or indication onthe upper surface of the top and bottom end tabs 106, 108. In oneembodiment, the top end tab 106 can be marked with an “A” indicating thetop of the process tube strip 100 and the bottom end tab 108 can bemarked with the letter of the alphabet corresponding to the number ofprocess tubes 102 in the process tube strip 100 (for example, an “H”would be marked on the bottom end tab 108 of the process tube strip 100for a process tube strip 100 having eight process tubes 102 connectedtogether in the process tube strip 100). The skilled artisan willreadily appreciate, however, that various other characters, e.g.,alphanumeric characters, such as “1” and “8” can also be readily used inmarking the top and bottom end tabs of process tube strip 100, toachieve the same purpose. Thus, the top and bottom end tabs 106, 108 canbe used to indicate the top and bottom of a process tube 102 and thenumber of process tubes 102 in a process tube strip 100. In addition,the end tabs 106, 108 can be marked with a color marking, a barcode, orsome other designation to identify, for example, the contents of theprocess tubes 102, the assay type being performed in the process tubestrip 100, and the date and location of manufacture of the process tubestrip 100.

FIG. 1D is another embodiment of the process tube strip 100 thatincludes a ledge extension 110 on each of the process tubes 102. FIG. 1Eis an additional embodiment of the process tube strip 100 that includesa tube tag 112 positioned on the ledge extension 110 of each processtube 102. These embodiments will be discussed in further detail below.

Process tubes 102 can be receptacles for, or house, solids or liquids.For example, process tubes 102 can hold reagents and/or samples, e.g.,nucleic acid samples to be used in amplification assays. The processtubes 102 can be circular in cross-section, but other cross sections arepossible and consistent herewith. The process tubes 102 can bemanufactured via a unitary construction, although in certain instancesthe process tubes may be constructed from two or more parts fused orotherwise joined together as applicable. Typically, the process tubes102 have an opening that is configured to accept/receive a pipette tipfor deposit and/or retrieval of fluids within the process tube 102.

In some embodiments, the process tubes 102 can be constructed frompolypropylene or other thermoplastic polymers known to those skilled inthe art. Alternatively, process tubes 102 can be constructed from otherappropriate materials, such as polycarbonate or the like. In someembodiments, the polypropylene is advantageously supplemented with apigment, such as titanium dioxide, zinc oxide, zirconium oxide, orcalcium carbonate, or the like. Preferably, the process tubes 102 aremanufactured using materials such that they do not fluoresce and thus donot interfere with detection of the amplified nucleic acid in theprocess tubes 102.

FIGS. 2A and 2B show, respectively, an isometric and a cross-sectionalview of an exemplary single process tube 102. Connector tabs 104 areshown in FIG. 2A, connecting the process tube 102 to other process tubes102 on either side of the process tube 102. In FIG. 2B, the shownconnector tab 104 includes a connector recess 232 on the underside ofthe connector tab. In some embodiments, the connector recess 232provides a separation point to easily break apart different processtubes 102 connected as part of a process strip 100. The process tubes102 can be broken apart by the end user in order to mix and matchdifferent process tubes 102 having different dried reagents, andrearranging the process tubes in the carrier tray 300 to match thenecessary operation of the amplification assay in the thermal cycler. Aconnector tab 104 can also be positioned between the process tube 102 atthe end of a process tube strip 100 and the top or bottom end tab 106,108. Such a connector tab 104 allows the end process tube 102 to beremoved easily and also mixed and matched with process tubes 102 fromother process tube strips 100 or to be used individually in a thermalcycler.

As shown in FIGS. 2A and 2B, the process tube 102 can have a top ring202, the top ring 202 defining an opening 226 at the top of the processtube 102. The top ring 202 extends around the circumference of theopening 226. As part of the process tube 102, an annular ledge 204extends laterally out from the side of the process tube 102 below thetop ring 202. In this manner, the top ring 202 extends upwards from anupper surface 206 of the annular ledge 204. In addition to the uppersurface 206, the annular ledge 204 is also defined by an outer surface208 and a lower surface 210. Below the annular ledge 204 is a neck 228of the process tube 102, which extends vertically from the annular ledge204, parallel to the longitudinal axis 230 of the process tube 102. Asshown in FIG. 2B, the exterior of the process tube 102 at the neck 228can be parallel to a longitudinal axis 230 running vertically throughthe process tube 102. In another embodiment, the exterior neck 228 canbe at an angle to the longitudinal axis 230 to aid in removal of theprocess tube 102 from an injection mold during the manufacturingprocess.

Below the neck 228 of the exemplary process tube 102 shown in FIGS.2A-2B, is a protrusion 212 extending laterally from the side of theprocess tube 102. The protrusion 212 is defined by an upper slope 214when extends from the neck 228 to an apex 215 of the protrusion 212. Theapex 215 of the protrusion 212 has the largest outside diameter of theprotrusion 212 and then the protrusion 212 includes a lower slope 216which extends from the apex 215 down the exterior of the process tube102. The upper slope 214 of the protrusion 212 slopes away from thelongitudinal axis 230 and the lower slope 216 slopes back towards thelongitudinal axis 230. In some embodiments, as shown in FIGS. 2A-2B, theangle of the upper slope 214 on the protrusion is steeper than the angleof the lower slope 216 on the protrusion 212. The lower slope 216 of theprotrusion 212 meets a longer body portion 218 of the process tube 102.The body 218, like the lower slope 216 of the protrusion 212, slopestowards the longitudinal axis 230, but has a less steep angle than thelower slope 215 of the protrusion 212. The body 218 extends to a base220 of the process tube 102. The base 220 includes an annular bottomring 224 on the bottom of the process tube 102, defined by a divot 222in the bottom of the process tube 102. In this embodiment, the top ring202, the annular ledge 204, the neck 228, the protrusion 212, and thebody 218 are coaxial with the longitudinal axis 230.

The annular ledge 204, neck 228, and protrusion 212 together define asecurement region 200 of the process tube 102. As will be explained indetail below, the securement region 200 provides a way to easily andsecurely attach the process tube 102 (or plurality of process tubes 102in the form of a process strip 100) to a carrier tray for transport andlater processing in the heater of an thermal cycler.

As described above, the process tubes 102 can be manufactured as a strip100 of tubes 102 connected together by a connector tab 104. Multipleprocess tube strips 100 can then be inserted securely in a carrier tray300. FIG. 3A shows an exemplary carrier tray 300. As seen in FIG. 3A,the carrier tray 300 can house a plurality of ports 306 in a shelf 302of the carrier tray 300. The plurality of ports 306 can be configured toreceive the individual process tubes 102, and the number of ports 306 ina column of the carrier tray 300 can be advantageously designed to fitthe length of the process tube strips 100. Thus, the number of ports 306in the y-direction can be designed to correspond to the number ofprocess tubes 102 in a process tube strip 100. In one embodiment, thecarrier tray 300 can have eight ports 306 in the y-direction such that aprocess tube strip 100 consisting of eight process tubes 102 can beinserted and secured in the ports 306 of the carrier tray 300 in they-direction.

In one embodiment, the ports 306 in the carrier tray 300 are ellipticalin shape, having a larger cross-sectional diameter in the y-direction.In this manner, the larger diameter cross-sections of the ellipticalports 306 are lined up in the same direction as the process tube strips100 when inserted in the carrier tray 300.

FIG. 3B shows a plurality of process tube strips 100 securely fit in anexemplary carrier tray 300. Once the process tubes 102 are insertedsecurely in the carrier tray 300, assay reagents, e.g., amplificationand detection reagents, can be added to the process tubes 102 in anautomated manner. In some embodiments, liquid reagents can be pipettedinto the individual process tubes 102 and then the carrier tray 300 canoptionally be placed in a drier to dry the liquid reagents in the bottomof the process tubes as a solid mass formed to the shape of the internalbase 220 of the process tube 102. In some embodiments, liquid reagentsare not dried down in the process tubes 102. In some embodiments, eachprocess tube 102 in a carrier tray 300 can be deposited with identicalreagents. In other embodiments, some or each of the process tubes 102 inprocess tube strip 100 can be filled with differing reagents or samples.

Once filled with the desired reagents, e.g., following drying of thereagents in embodiments wherein the reagents are dried, or simplyfollowing deposition of the reagents in embodiments wherein the reagentsare not dried, the process tubes 102 can be marked with an indicator toidentify the contents (for example, the specific reagents) of theprocess tubes 102. In some embodiments, marking of the process tubes 102can be accomplished by hot stamping the top ring 202 of the processtubes 102 with a specific color indicating the contents (e.g., reagents)of the process tubes 102. The top ring 202 also provides a surface towhich an adhesive seal can be applied to seal the opening 226 of theprocess tube 102.

As described above, FIG. 1D shows a process tube strip 100 wherein eachprocess tube 100 includes a ledge extension 110 extending from one sideof the annular ledge 204 of the process tube 100. The ledge extension110 provides additional surface area on the annular ledge 204 formarking of the individual process tubes 102. In one embodiment, theledge extension 110 can be pre-marked with an alphanumeric identifier(e.g., A, B, C, etc, or 1, 2, 3, etc.) to identify an individual processtube 102 within a process tube strip 100. In one embodiment, as analternative to hot stamping the top ring 202, the ledge extension 110 ofthe process tubes 102 can be hot stamped, or otherwise marked, toidentify the contents (e.g., reagents) of the process tubes 102following the deposit of the reagents in the process tubes 102.Furthermore, a 2-D bar code (ink or laser) can be printed directly onthe ledge extension 110.

As shown in FIG. 1E, the individual process tubes 102 of the processtube strip 100 can include a tube tag 112 affixed to the top of theledge extension 110. The tag 112 can be used in addition to, or inconjunction with, marking (e.g., hot stamping) the top ring 202 of theprocess tubes 102 to identify the contents, such as reagents, in aparticular process tube 102. The tag 112 can be a 2-dimensional matrixbar code (for example, a QR code or Aztec code) encoded with dataidentifying the contents of the associated process tube 102. In using atag 112 to indicate the contents of the process tube 102, a camera(e.g., a CCD camera) can be used to scan and verify the contents of theprocess tube 102 and ensure the correct amplification assays are beingperformed with the associated reagents. The camera can efficiently andquickly verify the contents of each process tube 102 by reading the tag112, thus avoiding the possibility of user error in pairing incorrectreagents with a specific amplification assay required for a givenpolynucleotide sample.

In some instances, identical reagents can be added to each process tubein a carrier tray 300. In one example, each tube strip 100 can includeeight process tubes 102 and then 12 tube strips can be securely fit intoa 96-port carrier tray 300. Identical reagents can then be added to eachof the 96 process tubes in the carrier tray 300. If all process tubes102 are provided with identical reagents, all process tubes 102 in theentire carrier tray 300 can be hot stamped with the same color. A numberof carrier trays 300 can be stacked and sent together to the end user.In some embodiments, each or some of the process tubes 102 in tube strip100 can include different reagents. In such instances, process tubes 102that contain identical reagents can be marked with the same color.Different colors can be used to identify process tubes 102 containingdifferent reagents.

The end user may need different stamped process tubes 102 to rundifferent amplification assays with the different reagents provided. Insome instances the end user may need to use different reagents in anamplification assay, so a carrier tray 300 having process tubes 102 ofall the same reagents could not be used. In this case, the end user canremove one or more process tube strips 100 from a single-color carriertray 300 and exchange them with differently colored process tube strips100 in a different carrier tray 300 to achieve the desired number andtype of reagents for a given amplification assay. It is alsocontemplated that the manufacturer could provide the end user with acarrier tray 300 having different colored process tube strips 100.

The end user can further refine the collection of different reagents inan amplification assay by breaking apart an individual process tubestrip 100 at the connector recess 232 between process tubes 102. Forexample, an eight-tube process tube strip 100 can be broken into smallercollections of process tubes 102 having 1, 2, 3, 4, 5, 6, or 7 processtubes 102. Breaking apart the process tube strips 100 allows the enduser to include process tubes 102 of different reagents in the samecolumn of the carrier tray 300.

As described above, FIG. 3B provides an illustration of the processtubes 102 when the process tubes are already securely fit into thecarrier tray 300. FIG. 4 is a cross-sectional view of 12 process tubes102 positioned in the carrier tray 300 prior to securing the processtubes 102 in the carrier tray 300. This view is analogous to thecross-sectional view 6A shown in FIG. 3, but shows the process tubes 102resting in the ports 306 of the carrier tray 300 prior to securing theprocess tubes 102 in the carrier tray 300. As shown in FIG. 3B and FIG.4, the carrier tray 300 has a base 304 and a shelf 302, the base 304being wider and longer than the shelf 302 and, thus, having a largerplanar surface area than shelf 302. The shelf 302 of the carrier tray300 includes a shelf side 308 and a shelf top 310. The shelf top 310 isthe horizontal, planar portion of the shelf 302 and covers the top ofthe carrier tray 300. The shelf top 310 includes an exterior surface 312and an interior surface 314. As the base 304 of the carrier tray 300 iswider and longer than the shelf 302, the base 304 includes a bridge 320running horizontally connecting the shelf side 308 and a base side 305.The bridge 320 includes an interior side 322. The shelf side 308 of theshelf 302 on the carrier tray 300 extends down from the shelf top 310and joins the base 304 of the carrier tray 300 at the bridge 320. Asshown in FIG. 4, the process tubes 102 of a process tube strip 100 canbe positioned in the ports 306 in the shelf 302 of the carrier tray 300.

FIG. 5 is a close-up, cross-sectional view of two exemplary processtubes 102 positioned in an exemplary carrier tray 300, prior to securingthe process tubes 102 in the carrier tray 300. Prior to securing aprocess tube 102 in the carrier tray 300, the process tube 102 is ableto rest in the port 306 of the carrier tray 300. The outside diameter ofthe body 218 of the process tube 102 is smaller than the diameter of theport 306, thus, the body 218 of the process tube 102 can be insertedthrough the port 306. The protrusion 212 on the process tube 102 has alarger diameter than at least one diameter of the port 306. For example,in the instance of the port 306 being elliptical, the smaller diameterof the port 306 (for example the width diameter in the x-direction ofFIGS. 3A and 3B) is smaller than the diameter of the protrusion 212. Insome embodiments, the larger diameter of the port 306 (for example thelength diameter in the y-direction of FIGS. 3A and 3B) can be largerthan the diameter of the protrusion 212. Thus, when the body 218 of theprocess tube 102 is inserted into the port 306, the body 218 enters theunderside area of the carrier tray 300, but a top portion of the processtube 102, including the securement region 200 (comprising the protrusion212, the neck 228, and the annular ledge 204) and the top ring 202, isprevented from entering the port 306. In this manner, the protrusion 212comes to rest on a top edge 318 of the port 306. More specifically, thelower slope 216 of the protrusion 212 comes to rest on the port top edge318.

In some embodiments, the apex 212 of the protrusion 212 is circular,having a constant outside diameter. For an elliptical port 306, in oneembodiment, the port 306 can have a length diameter larger than thewidth diameter. In this embodiment, the diameter of the port 306 width(in the x direction) can be less than the diameter of the apex 215 ofthe protrusion 212. Thus, the process tube 102 comes to rest, at theprotrusion 212, on the top edge 318 of the port 306. In one embodiment,the length diameter (in the y direction) of the port 306 can be greaterthan the diameter of the apex 215 of the protrusion 212. Thus, a smallgap on two ends (in the y-direction) of the port 306 is provided thatfacilitates easier securement of the process tube 102 in the port 306and also facilitates easier removal of the process tube 102 from theport 306, if needed. In other embodiments, the port 306 can be round,having a constant diameter.

As the process tube 102 rests in the port 306 against the port top edge318, a force can be applied to the top of the process tube 102 to pressthe process tube 102 further into the port 306 to secure the processtube 102 in the port 306 of the carrier tray 300. The force to securethe process tube 102 into the port 306 can be applied to the top ring202 of the process tube 102 or the force can be applied to the uppersurface 206 of the annular ledge 204.

Securing the process tube 102 in the port 306 initially involvesapplying sufficient force to the top of the process tube 102 to forcethe lower slope 216 of the protrusion 212 into the port 306. The lowerslope 216 is angled towards the longitudinal axis 230 of the processtube 102. As continued pressure is applied to the top of the processtube 102, the lower slope 216 of the protrusion 212 slides down alongthe port top edge 318 until the apex 215 of the protrusion 212 reachesthe port top edge 318. The port top edge 318 can be rounded or sloped tofacilitate the travel of the protrusion 212 through the port 306.

As the process tube 102 is pushed into the port 306, the portions of thelower slope 216 of the protrusion 212 that have passed into the port 306do not contact the port interior wall 316 because the lower slope 216 isangled towards the longitudinal axis 230. The lower slope 216 of theprotrusion 212 gradually widens (the outside diameter increases) as thelower slope 216 extends upwards towards the apex 215 of the protrusion212. The wider the diameter of the lower slope 216, the greaterresistance to pushing the process tube 102 into the port 306. Thus, aresistive force is generated which counters the force applied to pushthe process tube 102 into the port 306. The resistive force against theprocess tube 102 increases (and the force necessary to push the processtube 102 increases), the farther down the process tube 212 travels intothe port 306. The resistive force against the process tube 102 continuesto increase until the apex 215 of the protrusion 212 reaches the porttop edge 318.

In an embodiment of the carrier tray 300 having elliptical ports 306,the larger diameter of the port 306 in the y direction may more easilyallow the process tube 102 to be pushed into the port 306 and secured inthe carrier tray 300, thus reducing the force required to secure theprocess tube. An elliptical port 306 can provide extra space (e.g., agap) between the protrusion 212 of the process tube 102 and the portinterior 316 on two ends that allows the process tube 102 to flex andelongate in the y direction and compress in the x direction.

Once the entirety of the lower slope 216 passes through the port topedge 318, and the apex 215 of the protrusion passes through the port topedge 318, the apex 215 of the protrusion 212 comes into contact with theport interior wall 316. The apex 215 is the widest portion (largestoutside diameter) of the protrusion 212. As the apex 215 is being fitthrough the port 306 and pressed against the port interior wall 316, theprocess tube 102 undergoes maximum strain and is maximally flexed. Ascontinued force is applied to the top of the process tube 102, the apex215 is forced to slide down the port interior wall 316 until itcompletely passes through the port 306 at the bottom edge 319 of theport 306. Once the apex 215 breaches the bottom edge 319, the strain onthe process tube 102 is released and the process tube 102 “snaps”securely into place in the port 306 and becomes secured in the carriertray 300. The force necessary to secure each process tube 102 of theprocess tube strips 100 in a carrier tray 300 can range fromapproximately 0.7 lbs. force to approximately 1.7 lbs. force. In oneembodiment, the force necessary to insert and secure process tube 102 ina port 306 can be approximately 1 lb. force. In one embodiment, theforce necessary to secure a process tube 102 in a port 306 can beapproximately 1.18 lbs. force.

The carrier tray 300 can be advantageously designed for efficientstacking and transport of the carrier trays 300. The carrier tray 300can be constructed from polycarbonate resin thermoplastic. Referring toFIGS. 3, 4, and 5, the carrier tray 300 can include a bridge 320 at thetop of the base 220. The bridge 320 provides a platform on which thebottom surface 326 of another empty carrier tray 300 can positioned.When two carrier trays 300 are stacked on top of each other, the bridgeinterior 322 of a top carrier tray 300 comes to rest on the shelf top310 of a bottom carrier tray 300 and the bottom surface 326 of the topcarrier tray 300 comes to rest on the bridge 320 of the bottom carriertray 300.

When the carrier trays 300 are populated with the process tube strips100, they can be efficiently stacked in a similar manner. The body 218of the process tubes 102 in a top carrier tray 300 can be placed in theopening 226 of the process tubes 102 in a bottom carrier tray 300.Likewise, the process tubes 102 in the top carrier tray 300 can furtherreceive the body 218 of the process tubes 102 in another carrier tray300 to be stacked on top of it.

FIG. 6A is a cross-sectional view, taken along line 6A in FIG. 3B, ofthe 12 process tubes 102 shown in FIG. 4. FIG. 6A shows the processtubes 102 now secured in the carrier tray 300. The direction ofcross-section 6A in FIG. 3B provides a view of 12 process tubes 102,each from a different process tube strip 100. FIG. 6B is across-sectional view, taken along line 6B in FIG. 3B, of an entireprocess tube strip 100 positioned in the carrier tray 300 after securingthe process tubes 102 in the carrier tray 300. As shown in FIG. 6B, thecross-sectional diameter of the elliptical port 306 in the y directioncan be larger than the diameter of the protrusion 212.

FIG. 7 is a close-up view of two of the process tubes 102 shown in FIG.6A and corresponds to the process tubes 102 of FIG. 5 after securing theprocess tubes 102 in the carrier tray 300. As shown in FIG. 7, thecross-sectional diameter of the elliptical port in the x direction canbe smaller than the diameter of the protrusion 212. When the apex 215 ofthe protrusion 212 breaches the bottom edge 319, the upper slope 214 ofthe protrusion 212 comes into contact with, and lodges against, thebottom edge 319 of the port 306, at the bottom of the securement region200. Also, when the apex 215 breaches the bottom edge 319, the lowersurface 210 of the annular ledge 204 comes into contact with, and lodgesagainst, the shelf top exterior 312 of the shelf 302, at the top of thesecurement region 200. At the top of the securement region 200, theannular ledge 204 is sufficiently wide at least two points around theport 306 that the annular ledge 204 cannot pass through the port 306. Inone embodiment, the annular ledge 204 can have a sufficiently largediameter to cover all points around the port 306. For example, theannular ledge 204 can have a larger diameter than the width and lengthdiameters of the port 306. The height of the securement region 200 (fromthe lower surface 210 of the annular ledge 204 to a location on theupper slope 214 of the protrusion 212) corresponds approximately to theheight of the port 306, between the port top edge 318 and the portbottom edge 319.

As shown in FIG. 7, the neck 228 of the process tube 102 can have asmaller outside diameter than the diameter of the port 306, creating agap 324 between the process tube 102 and the port interior wall 314. Inone embodiment, the outside diameter of the neck 228 can be a fixedcircular diameter. As the port 306 can be elliptical in shape and have alarger length diameter on one side and a smaller width diameter on theother side, the width of the gap 324 can vary between the length side (ydirection) and width side (x direction) of the port 306. For example,the size of the gap 324 on each length side of the port 306 can beapproximately twice the size of the gap on each width side of the port306.

The gap 324 provides a point of adjustment for the process tube 102 inthe securement region 200. The gap 324 exists primarily between the neck228 of the process tube 102 and the port interior wall 316, but the gap324 also exists along a portion of the upper slope 214 of the protrusion212 and along a portion of the lower surface 210 of the annular ledge204. The gap 324 is enlarged slightly at the top portion of thesecurement region 200 because the rounded corners of the port top edge318 provide additional distance between the port 306 and the neck 228 ofthe process tube 102. The gap 324 can provide the process tube 102 somedegree of freedom of movement within the port 306 of the carrier tray300, even when the process tube 102 is secured in the port 306.

The process tube 102 can be adjusted in the port 306 while beingmaintained securely in the port 306 because the point of contact betweenthe upper slope 214 of the protrusion 212 and the port bottom edge 319can adjust as the process tube 102 needs to tilt. When a process tube102 tilts, the locations of the points of contact between the securementregion 200 of the process tube 102 and the port 306 of the carrier tray300 will adjust. For example, when the process tube tilts to one side, apoint of contact on one side of the process tube 102 between the upperslope 214 and port bottom edge 319 moves near the top of the upper slope214; on the other side of the tube, another point of contact moves to benear the bottom of the upper slope 214 (near the apex 215). Similaradjustment is possible at the top of the securement region 200, suchthat the neck 228 can be tilted towards the rounded port top edge 318 onone side of the process tube 102 and can be tilted away from the porttop edge 318 on the other side of the process tube 102.

The gap 324 allows the process tube 102 to adjust when placing aplurality of process tubes into the carrier tray 100 as part of aprocess tube strip 100. Because of possible manufacturing variations ofthe carrier trays 300 and the process tubes 102, each carrier tray 300may be sized slightly differently and each process tube 102 may fit inthe carrier trays 300 differently. Given that the process tubes 102 areoften attached together as part of a process tube strip 102 wheninserted in the carrier tray 300, it is possible that, withoutmitigating considerations, the manufacturing variations of the carriertray 300 and process tubes 102 could prevent accurate placement of anentire process tube strip 100 in a carrier tray 300. For example,accurate insertion of a process tube 102 at one end of a process tubestrip 100 into the carrier tray 300 could prevent accurate insertion ofthe process tubes 102 at the other end of the process tube strip 100into the carrier tray 300 because the process tubes 102 could bemisaligned in either the x direction (lateral) or y direction (front toback). Even if a rigid process tube strip 100 is forced into the ports306 of a carrier tray 300 despite being misaligned, the rigid attachmentof the process tubes 102 would prevent the process tubes 102 from lyingflat on the carrier tray 300 which could inhibit the hot stampingprocess.

The present disclosure addresses these issues in a number of ways,including allowing the process tubes 102 to tilt and adjust in the port306 when the process tube strip 100 is being maneuvered and inserted inthe carrier tray 300. The process tubes 102 can tilt and adjust in theport 306 because the gaps 324 allow for such motion. The ellipticalshape of the ports 306 also enhances the adjustment available in the ydirection. Also, the connector tabs 104 connecting the process tubes 102are thin and pliable enough to allow maneuverability and adjustmentbetween the individual process tubes 102 when inserting them in thecarrier tray 300. In addition, the connector recess 232 (seen in FIG.2B) on the connector tab 104 allows increased flexibility between theindividual process tubes 102 when inserting them in the ports 306. Inthis manner, the gaps 324, the elliptical-shaped ports 306, and theconnector tabs 104 afford the process tube 102 the capacity to adjustand always lay flat on the carrier tray 300 when inserting a processtube strip 100 into the carrier tray 300. Furthermore, the capacity of aprocess tube 102 to tilt or adjust in the carrier tray 300 facilitiesinsertion of the process tube 102 into a heater of the thermal cycler,as discussed below in more detail.

When the process tubes 102 are secured in the ports 306 of the carriertray 300, the process tubes 102 can undergo processing in preparationfor use in a thermal cycler. Liquid reagents can be inputted into thesecured process tubes 102. The process tubes 102 in the carrier tray 300can be subjected to heat or other processes for drying or lyophilizationin order to dry the liquid reagents in the process tubes 102. Whilesecured in the carrier tray 300, the process tubes 102 can also be hotstamped to mark the process tubes 102, indicating the type of reagentsadded to the process tubes 102. The hot stamping can be in the form of acolor stamped on the top ring 202 and/or the annular ledge 204.

The process of applying force to securing the process tubes 102 in theports 306 of the carrier tray 300, the process of inputting liquidreagents into the secured process tubes 102, the process of drying theliquid reagents in the process tubes 102, and the process of hotstamping the process tubes 102 in carrier tray 300 can all be automatedand performed at the site of manufacture and assembly of the processtubes 102 and carrier trays 300. The assembled carrier trays 300containing the prepared process tubes 102 can then be shipped to the enduser for additional processing such as depositing extracted nucleic acidsamples in the process tubes 102 prior to running amplification assayson the samples the process tubes 102 in a thermal cycler. The additionof the extracted nucleic acid samples to the process tubes 102 acts toreconstitute the dried reagents to allow the reagents to associate withthe nucleic acid samples in the reconstituted solution.

As described above, an end user can remove one or more process tubestrips 100 from a single-color carrier tray 300 and exchange them withdifferently colored process tube strips 100 in a different carrier tray300 to achieve the desired number and type of reagents for a givenamplification assay. The force necessary to remove the process tubestrip 100 can be approximately half of the force required to insert it.In one embodiment, the insertion force for a process tube strip 100 canhave a range of approximately 0.7 lbs. force to 1.7 lbs. force and theremoval force for the process tube strip 100 can have a range ofapproximately 0.3 lbs. force to 0.8 lbs force. In one embodiment, theinsertion force for a process tube strip 100 can be approximately 1 lb.force and the removal force for the process tube strip 100 can beapproximately 0.5 lb. force. In one embodiment, the force necessary tosecure a process tube strip 100 in the ports 306 can be approximately1.18 lbs. force and the force necessary to remove the process tube stripis 0.60 lbs. force. The insertion and removal forces prescribed for theprocess tube strips 100 insure that a process tube strip 100 is notoverly difficult to insert or remove from the carrier tray 300 and alsoprevent the process tube strips 100 from falling out of the carrier trayunder normal handling conditions.

It is of note that the same carrier tray 300 (housing the process tubes102) in which the mixing of reagents and nucleic acid samples occurs canbe input directly into the thermal cycler. Thus, the end user is notrequired to do the mixing of reagents and nucleic acid in one tube andthen transport that mixed solution to another tube, or even move thefirst tube to another tray. In the present disclosure, the process tubes102 containing the reagents and secured in the carrier tray 300 canreceive the samples, e.g., nucleic acid samples, and, then withoutremoving the process tubes 102 from the carrier tray 300, can be inputinto the thermal cycler for amplification assays.

It is also contemplated that solid reagents may be added to the processtubes 102 in addition to, or instead of, the liquid reagents. It is alsocontemplated that empty process tubes 102 and carrier trays 300 can besupplied to the end user and the end user can deposit the solid orliquid reagents in the process tubes 102 prior to adding the nucleicacid samples.

The securement force, the force necessary to push the process tube 102securely into the port 306, can be applied simultaneously to multiple(or all) process tubes 102 in the carrier tray 300. Alternatively, thesecurement force can be applied separately to individual process tubes102 one at a time, as needed. The securement force can be applied in anautomated manner and can be conducted concurrently along with theautomated steps of filling the process tubes 102 with reagents and hotstamping the process tubes 102. In some instances, the same apparatuscan be used to hot stamp and apply the securement force to the processtubes 102. Alternatively, separate apparatuses can be used for hotstamping and applying the securement force.

When a separate securement force device and a hot stamping device areused, the securement force can first be applied to secure the processtubes 102 in the ports 306 of the carrier tray 300 prior to hot stampingthe top ring 202 of the process tubes 102. In some instances, theautomated hot stamping apparatus may stick to the top ring 202 of theprocess tubes 102 when applying pressure to the top ring 202. Because ofthe novel way in which the process tubes 102 are secured in the carriertray 300 in the embodiments described herein, a process tubes 102 arenot pulled up and out of the carrier tray 300 when the hot stampingapparatus pulls apart from the process tube 102 being stamped.Furthermore, because the process tubes 102 are secured in the carriertray 300, the process tubes 102 can be transported without risk of theprocess tubes 102 falling out of the carrier tray 300. The embodimentsdisclosed herein also advantageously overcome other issues that presentin other PCR tube trays, such as bunching of tubes on one side of thetray or tubes falling out of alignment in the tray.

FIG. 8 is an isometric view of an exemplary heater assembly 400 to beused in a thermal cycler (not shown). Amplification assays (such as PCRor isothermal amplification) can be performed in the thermal cycler. Theheater assembly 400 is part of temperature cycling-subsystem of thethermal cycler and can work in conjunction with other subsystems of thethermal cycler, such as a detection subsystem. The exemplary heaterassembly 400 shown in FIG. 8 is a 96-well assembly containing 96 heaterwells 402, although other assemblies are contemplated (e.g., 48-wellassemblies, etc.). The heater assembly 400 includes a flat top surface404 between the heater wells 402, and a side surface 410. Each heaterwell 402 is conical in shape and is comprised of an interior wall 406and a well bottom 412. The heater wells 402 in the heater assembly 400are arranged in an array of 8 rows and 12 columns to correspond to thespatial arrangement of process tubes 102 in a carrier tray 300.

Each heater well 402 can receive a process tube 102. The carrier tray300 can be placed directly over the heater assembly 400 in the thermalcycler in order to place all process tube 102 in the carrier tray 300into the heater assembly 400 simultaneously. Not shown in FIG. 8 is thecasing around the heater assembly 400 or the necessary circuitry toprovide heat to the heater wells 402.

Because of possible manufacturing variations of the carrier trays 300and the process tubes 102, each carrier tray 300 may be sized slightlydifferently and each process tube 102 may fit in the carrier trays 300differently. If the process tubes 102 were rigidly attached to thecarrier tray 300, the manufacturing tolerances could prevent all of theprocess tubes in a 96-tube carrier tray 300 from accurately being placedin the heater wells 402. For example, fitting a process tube 102 in aheater well 402 on one side of the heater assembly 400 may prevent aprocess tube 102 on the other side of the heater assembly 400 from beingaccurately and securely placed into its respective heater well 402. Asdescribed above, the process tubes 102 are able to float or adjustslightly when secured in the carrier tray 300 because of the gap 324between the port interior wall 316 and the securement region 200 of theprocess tube 102. The connector recess 232 (seen in FIG. 2B) on theconnector tab 104 also allows flexibility between the individual processtubes 102 when inserting them in the heater wells 402. Allowing theprocess tubes 102 to float within ports 306 of the carrier tray 300permits the process tubes 102 to adjust position to fit accurately andsecurely into the heater wells 402 of the heater assembly 400.

FIG. 9 is a cross-sectional view of two exemplary process tubes 102positioned in heater wells 402 of the heater assembly 400. When theprocess tube 102 is placed in the heater well 402, the body 218 of theprocess tube 102 comes in physical contact with, and is mated to, theinterior wall 406 of the heater well 402. In some embodiments, theheater well 402 is deeper than the body 218 of the process tube 102,such that when the process tube 102 is secured in a port 306 of thecarrier tray 300 and the carrier tray 300 is positioned over the heaterassembly 400, the base 220 of the process tube 102 does not extend tothe well bottom 412. In this manner, a gap 414 is created between thebase 220 of the process tube 102 and the well bottom 412. The gap 414ensures that the body 218 of the process tube 102 remain in physicalcontact with the well interior wall 406; if the base 220 of the processtube 102 were to bottom out in the heater well bottom 412 first, beforethe body 218 contacts the well interior wall 406, a gap could existbetween the wall 406 and the body 218 of the process tube 102 and causepoor heat transfer between the heater well 402 and the process tube 102.Thus, the gap 414 below the process tube 102 ensures that a gap does notexist between the wall 406 and the body 218 of the process tube 102. Theheater well 402 can surround the body 218 of the process tube 102 andprovide uniform heating to the contents of the process tube 102 duringthe thermal cycling steps of the amplification assay. When the processtube 102 is placed in the heater well 402, the heater well 402 cansurround the body 218 of the process tube to a location just below thelower slope 216 of the protrusion 212.

The above description discloses multiple methods and systems of theembodiments disclosed herein. The embodiments disclosed herein aresusceptible to modifications in the methods and materials, as well asalterations in the fabrication methods and equipment. Such modificationswill become apparent to those skilled in the art from a consideration ofthis disclosure or practice of the invention disclosed herein.Consequently, it is not intended that the embodiments disclosed hereinbe limited to the specific embodiments disclosed herein, but that itcover all modifications and alternatives coming within the true scopeand spirit of the invention.

Example 1

This example illustrates a specific process for preparing a carrier tray300 with process tubes 102 to be provided to an end user.

-   -   1. Manufacturing 12 process tube strips containing eight        connected process tubes formed from polypropylene.    -   2. Manufacturing a carrier tray from polycarbonate having 96        ports in an 8×12 array.    -   3. The 12 process tube strips are placed in the carrier tray.    -   4. The process tubes of the process tube strips are secured in        the ports of the carrier tray by applying a force to the top        ring of the process tube.    -   5. Each process tube in the carrier tray is filled with the same        specific liquid reagents.    -   6. The carrier tray is heated to dry the reagents in the process        tubes.    -   7. The process tubes are hot stamped with specific colors to        indicate the assay for which they will be used.    -   8. The carrier tray is stacked and packaged with other carrier        trays having the same or different reagents and shipped to the        end user.    -   9. The end user can use the entire carrier tray as is, or may        depopulate the carrier tray and repopulate the carrier tray or        trays with a mix of individual process tube strips or tubes of        various reagent types.

Example 2

This example describes the test procedure and results of a test todetermine the force necessary to secure the process tube strips 100 inthe ports 306 of the carrier tray 300 and the force necessary tosubsequently remove the process tube strips 100 from the ports 306.

An Amtek AccuForce Cadet Force Gage, (0-5 lbs) was used to measure theforce necessary to secure and remove the process tubes 102 in the ports306.

Test Procedure

-   -   1. Lay one strip of tubes in a column of the carrier tray. (Not        yet secured in the carrier tray)    -   2. Turn on the gage.    -   3. Zero the gage with the gage in the upright position.    -   4. Clear the gage.    -   5. Slowly press down on each tube within the strip starting at        the “A” row with the gage at a slight angle ˜2-3 degrees from        vertical on each tube until all the tubes snap into place.    -   6. Record the force value on the gauge and the column number as        insertion values.    -   7. Press the clear button to clear the memory.    -   8. Lay the second strip of tubes in the second column. Repeat        steps 5-7.    -   9. Repeat steps 5-7 for the remaining strips 3-12.    -   10. Turn the carrier tray upside down and starting with the        first strip slowly press the tubes out of the carrier starting        at the “A” row.    -   11. Record the force value and the column number as removal        values.    -   12. Press the clear button to clear the memory.    -   13. Repeat steps 10, 11 and 12 for the remaining process tube        strips.    -   14. Rearrange the 12 process tube strips in the carrier tray and        repeat steps 3-13.

Results

The results of the force testing are provided in Table 1. Table 1 showsthe force necessary to insert and secure all the process tubes 102 of aprocess tube strip 100 in a carrier tray 300. As shown, the averageinsertion force to secure the process tube strips 100 in the carriertray 300 was 1.18 lbs force and the average removal force was 0.60 lbsforce.

TABLE 1 Process Tube Insertion and Removal Testing Tube Strips 1^(st)Round 1 2 3 4 5 6 Insertion 0.708 1.084 1.137 1.467 0.945 1.476 Removal0.313 0.478 0.573 0.589 0.520 0.518 1^(st) Round 7 8 9 10 11 12 AvgInsertion 0.866 1.075 1.408 0.969 1.025 1.217 1.115 Removal 0.553 0.9780.767 0.388 0.602 0.485 0.564 2^(nd) Round - tube strips randomlyrearranged 1 2 3 4 5 6 Insertion 0.668 0.904 1.661 1.727 1.677 1.296Removal 0.439 0.534 0.699 0.630 0.584 0.652 2^(nd) Round - tube stripsrandomly rearranged 7 8 9 10 11 12 Avg Insertion 1.536 1.051 1.280 1.0561.012 0.983 1.238 Average Insertion 1.18 Removal 0.723 0.675 0.778 0.7500.619 0.514 0.633 Average Removal 0.60

What is claimed is:
 1. A system comprising: a plurality of process tubesconnected together as a process tube strip and a carrier tray, eachprocess tube configured to removably and securely fit within a separateport of a plurality of ports of the carrier tray, wherein a firstprocess tube and a second process tube of the process tube strip eachcomprise: an annular ledge extending laterally from the process tube andcoaxial with a longitudinal axis running vertically through the processtube, the annular ledge comprising an upper surface, a lower surface,and an outer surface; a top ring extending vertically up from the uppersurface of the annular ledge and defining an opening to the processtube; an annular protrusion extending laterally from the exterior of theprocess tube, at a location on the process tube below the annular ledge,the protrusion having a rounded apex, an upper slope, and a lower slope,wherein the angle of the upper slope on the protrusion relative to thelongitudinal axis is steeper than the angle of the lower slope on theprotrusion relative to the longitudinal axis; a neck between the annularledge and the protrusion; a body below the protrusion; and a basedefining a bottom of the process tube; and wherein, after the firstprocess tube is removably inserted in the respective port of the carriertray, the first process tube is configured to tilt within a gap betweenthe neck of the first process tube and the interior wall of the port,wherein a width of the gap varies between a length side dimension and awidth side dimension of the port, and wherein the first process tube isconfigured to tilt more within the gap on the length side dimension thanwithin the gap on the width side dimension, and wherein the firstprocess tube and the second process tube are connected by a connectortab extending between the annular ledges of the first process tube andthe second process tube, the connector tab comprising a connector recesson an underside thereof.
 2. The system of claim 1, wherein the carriertray comprises a shelf and a base, the shelf comprising the plurality ofports through a top of the shelf, and the ports having an interior wall.3. The system of claim 2, wherein the ports of the carrier tray areelliptical in shape.
 4. The system of claim 3, wherein each portcomprises a length diameter that is larger than a width diameter.
 5. Thesystem of claim 4, wherein the protrusion of the first process tube hasa larger outside diameter than at least the width diameter of arespective port in the carrier tray.
 6. The system of claim 5, whereinthe neck of the first process tube has a smaller outside diameter thanthe length and width diameters of the respective port in the carriertray.
 7. The system of claim 2, wherein the first process tube issecurely fit into one of the plurality of ports of the carrier tray. 8.The system of claim 7, wherein the lower surface of the annular ledge ofthe first process tube rests on an exterior of the shelf top and theupper slope of the protrusion rests on a bottom edge of the interiorwall of the port.
 9. The system of claim 1, wherein the first processtube further comprises a planar extension extending laterally from theannular ledge, the extension providing a surface on which to mark theprocess tube.
 10. The system of claim 1, wherein the connector recess issized and shaped to increase flexibility between the first process tubeand the second process tube as the first process tube and the secondprocess tube are inserted into respective ports of the carrier tray, andwherein the connector tab is sized and shaped to ease removal of thefirst process tube and the second process tube from the respective portsof the carrier tray after the first process tube and the second processtube are inserted into the respective ports of the carrier tray.
 11. Thesystem of claim 1, wherein the connector recess is a separation point inthe process tube strip, whereby the first process tube is configured tobreak apart from the second process tube at the connector recess. 12.The system of claim 1, further comprising a heater assembly comprising aplurality of heater wells, each heater well comprising an inner wall anda well bottom, wherein at least the first process tube is received in aheater well of the plurality of heater wells such that the body of thefirst process tube contacts the inner wall of the heater well and aheater assembly gap is formed between a base of the first process tubeand the well bottom of the heater well, the heater assembly gapconfigured to prevent the first process tube from bottoming out in theheater well.
 13. A system comprising: a carrier tray comprising aplurality of elliptical ports therethrough, each port having a top edge,a bottom edge, an interior wall, and a length diameter that is largerthan a width diameter; and a process tube configured to removably snapinto an elliptical port of the plurality of elliptical ports of thecarrier tray, the process tube comprising a securement region on theexterior of the tube, the securement region comprising an annular ledge,an annular protrusion, and a neck between the annular ledge and theprotrusion, wherein the protrusion comprises a rounded apex, an upperslope from the rounded apex to the neck, and a lower slope from therounded apex to a body of the process tube, wherein the angle of theupper slope on the protrusion is steeper than the angle of the lowerslope on the protrusion, wherein a diameter of the neck is less than thelength diameter and the width diameter of the port, wherein a diameterof the protrusion at the rounded apex is larger than the width diameterof the elliptical port, wherein a cross-section of the process tube iscircular, and wherein, when the process tube is removably snapped intothe elliptical port, a gap is formed between the neck and the ellipticalport, a bottom surface of the annular ledge rests on a top surface ofthe carrier tray, and the upper slope of the protrusion contacts thebottom edge of the elliptical port, wherein the process tube isconfigured to tilt within the gap between the neck of the process tubeand the elliptical port, wherein a width of the gap varies between alength side dimension and a width side dimension of the elliptical port,wherein the process tube is configured to tilt more in the gap on thelength side dimension than in the gap on the width side dimension, andwherein the process tube is connected to a second process tube by aconnector tab extending between annular ledges of the process tube andthe second process tube, the connector tab comprising a connector recesson an underside thereof.
 14. The system of claim 13, wherein a diameterof the protrusion at the rounded apex of the process tube is configuredto decrease as the process tube is snapped into the elliptical port ofthe carrier tray.
 15. The system of claim 13, wherein a cross-section ofthe process tube is configured to elongate into the gap when theprotrusion is positioned within the elliptical port as the process tubeis snapped into the elliptical port of the carrier tray.
 16. The systemof claim 13, further comprising a heater assembly comprising a pluralityof heater wells, each heater well comprising an inner wall and a wellbottom, wherein the process tube is received in a heater well of theplurality of heater wells such that the body of the process tubecontacts the inner wall of the heater well and a heater assembly gap isformed between a base of the process tube and the well bottom of theheater well, the heater assembly gap configured to prevent the processtube from bottoming out in the heater well.
 17. The system of claim 13,wherein the process tube and the second process tube are removablysnapped into two elliptical ports of the plurality of elliptical portsof the carrier tray.